Long splice and method of making same



Nov. 22, 1966 D. w. GATHMAN LONG SPLICE AND METHOD OF MAKING SAME 3 Sheets-Sheet 5 Filed May 27. 1964 United States Patent O 3,286,452 LONG SPLICE AND METHOD F MAKING SAME David W. Gathman, Williamsport, Pa., assignor, by mesne assignments, to Bethlehem Steel Corporation, a corporation of Delaware Filed May 27, 1964, ser. No. 370,465 7 Claims. (cl. s7-14z) The present invention relates to the art of splicing sooalled long splices in lwire rope. More particularly, this invention relates t-o the formation of the tucks in long splices in wire rope having an independent wire core and a plurality of outer strands.

This invention is applicable to both non-tied and tied long splices. Such long splices are well known in the art and are dis-closed, for example, in U.S. Patent No. 190,823, issued to Ohannon, and U.S. Pa-tent No. 3,017,739, issued to the present inventor.

Various methods are known for tucking the loose ends of long splices. However, under certain conditions these methods have been unsatisfactory. For example, in nontied splices in short sections of wire rope, a tuck as disclosed by Channon cannot be made long enough to prevent the loose ends from pulling out. While the tuck disclosed in Patent No. 3,017,739 has been very succes-sful with quite st-itf wires, some diihculty has been encountered with wires working out of the rope when the rope is formed of the newer, stiiier wires.

It is an object of this invention to provide a tuck suitable for use in non-tied splices in short sections of wire rope.

It is a further object of this invention to provide a tuck which is suitable in ropes formed of the newer, stiffer wires.

It is a still further obje-ct of this invention to provide a tuck in a long splice in a wire rope which is resistant to disruptive forces under extreme operating conditions.

It is a further object of this invention to provide a method of forming an improved tuck in a long splice in wire rope, said tuck being easy for relatively inexperienced personnel to fabricate.

I have discovered that the foregoing objects can be attained by reducing the cross section of a section of the loose end of an outer strand, laying said reduced section in a helical void formed in the wire core by the removal of several contiguous strands therefrom, and inserting the remainder of said loose end in a cylindrical void formed in the center of the rope by removing a section of the wire core therefrom.

In the drawings:

FIGURES 1 through 7 illustrate sequentially the steps involved in making a tuck in a long splice. y

FIGURE 8 is a cutaway view of a completed tuck in a non-tied long splice.

Referring more particularly to the drawings, FIG- URE 1 shows a wire rope 21 having an independent multistrand wire core and a plurality of outer strands. While the invention may be applied to kany wire rope of this type, it will be illustrated with reference to a wire rope having two operation outer strands.

The wire rope 21 comprises two outer strands 23 and 25 which `are to be tucked into the rope. It is to be understood that one strand of strands 23 and 25 has been laid in the rope 21 from another wire rope, not shown, butted against or married to one end of rope 21.

As shown i-n FIGURE l, the first step in my method comprises reducing the cross section of the loose ends of outer strands 23 and 25. This is done by removing some of the component wires from said strands. In a two operation strand, the cross section is preferably reduced by unlaying the outer operation wires from the loose ends 3,286,452 Patente-d Nov. 22, 1966 ICC of strands 23 and 25 and cutting off and removing the inner operation wires 24 therefro`m. The outer operation wires of strands 23 and 25 are then again laid up together to form a reduced strand such as 23.

After the loose ends of strands 23 and 25 have been reduced in cross section, said strands may be tied in-to one or more knots as shown in FIGURE 2, themethod of tying said knots being disclosed in U.S. Patent No. 3,017,739. Although this step is vnot essential to the invention, it constitutes a preferred embodiment, and the following description will relate primarily to a tied long splice. It is noted that the remaining steps of my method are the same for both tied and non-tied long splices.

Inasmuch as both outer strands 23 and 25 are treated in the same manner, the remaining steps in the formation of the tuck will be illustrated with reference to the treatment of `strand 23 only, it being understood that strand 25 is treated in the same manner to complete the tuck.

The next `step in my method comprises forming a helical void in the wire core, the cross section of the void being substantially equal tothe cross section of the reduced section of strand 23. A preferred method of forming said helical void will next be described.

`As shown in FIGURE 3, rope 21 is pl-aced in a vise 28 and the outer strands separated close to where strand 23 leaves the knot by means of a marlinspikey 27 or other suitable tool. Several contiguous strands, eig. the three strands 29, 31 and 33, of the wire core 35 are then withdrawn and cut off. A

As shown in FIGURE 4, the three contiguous strands 29, 31, and 33 -are then unlaid for several lays and removed from the core of the rope. Preferably, said strands should be unlaid for substantially four lays.

The reduced section of strand 23 is next laid in the helical void. Inasmuch as the cross section of said reduced section is substantially equal to the cross section of said helical void, the diameter of the rope along t-he laid-in section is substantially equal to the normal diameterlof the rope.

The next step in my method comprises forming a cylindrical void in the center of wire rope 21 for a short distance beyond the laid-in section of strand 23. As shown in FIGURES 4 and 5, this is done by severing at the points 39 and 40 and removing a short section 41 of core 35 from the wire rope 21. The void so formed may vary in length, ydepending upon the diameter of the rope. A void approximately 16 inches long has been found satisfactory in a one inch diameter wire rope.

As shown in FIGURE 5, the remainder of the loose end of strand 23 is next built up to approximately the cross section of core 35 by the addition of wires 24A thereto to form a rebuilt section 45. The wires used for rebuilding may be new wires, but preferably are those wires which were removed as a rst step in the formationV of the tuck. The rebuilt section 45 is then inserted into the center of rope 21 in the cylindrical void 43 formed by the removal of section 41. FIGURE 6 shows section 45 being inserted into the cylindrical void 43 by means of a tucker 46.

The insertion of section 45 into the cylindrical void 43 in the center of the rope c-ompletes one half of the tuck. Strand 25 of rope 21 is then treated in the same way, resulting in the completion of one tuck of the long splice, as shown in FIGURE 7.

FIGURE 8 shows a cutaway view of a completed tuck in a non-tied long splice, the outer strands being stippled where they are tucked into the rope. As shown, outer strands 23 and 25 approach each other along the rope 21 and are reduced in cross section where they cross at point 53. Reduced sections 55 and 57 of outer strands 23 and 25, respectively, then lay in and grip a short severed section 47 of core 35. When the wire rope is subjected to tension, this short section 47 of wire rope core is placed in compression and bound in place. It is noted that the short section 47 of core 35 acts as a key to prevent the outer strands laid therein from being pulled out of the rope. FIGURE 8 Iclearly shows how the two outer strands 23 and 25 are effectively keyed to section 47.

While reduced sections 55 and 57 are shown laid in the core for only two lays, it is usually preferable to lay the reduced sections in the core for approximately four lays.

As a specific example of my tuck and method of forming said tuck, two pieces of one inch wire rope of 6 x 19 construction, each having an independent wire core, are brought together to form a conventional long splice. Each of the six strands is a two operation strand, the inner operation being composed of one center wire and six wires laid therearound with a certain length of helix or lay, and the outer operation being composed of twelve wires with a different length of helix. The wire rope core is a standard 7 x 7 wire rope consisting of six strands each laid around a seventh strand composed of seven wires.

The loose ends of two adjacent outer strands are first reduced in cross section by removing the center wire and the six wires laid therearound from each of said ends. The remaining wires in each of said ends are then laid together and the loose ends are tied in a single overhand knot.

A helical void is formed in the wire core on each side of the knot by removing three contiguous strands from the core for substantially four lays. Each of the loose ends is then laid in one of said helical voids.

A sixteen inch length of wire core is next removed from the center of the rope on each side of the laid-in loose ends. The remaining sections of the loose ends are then built up, using the previously removed wires, until the cross section of each is substantially equal to that of the core. The remaining sections of the loose ends lare inserted in the sixteen inch voids to complete the tuck.

As previously described, one method of forming the tuck comprises removing component wires from the loose ends of the outer strands and then, after laying a section of the outer strands in helical voids in the core, increasing the cross section of the remainder of the loose ends by adding wires thereto before inserting them into the cylindrical voids in the center of the rope. However, it is possible with careful measurement to remove wires from only those sections of the outer strands which are to be laid in the helical voids in the core. The remaining sections of the loose ends thus have their full oomplement of wires, and rebuilding operation is unnecessary.

It is to be understood that any number of contiguous strands may be removed from the core, the only requirement being that there be sucient room for the outer strands to be laid in the wire core without substantially increasing the diameter of the rope.

The improved tuck of the present invention is well adapted for use in non-tied long splices in short sections of wire rope. No diculties are encountered, even under severe operating conditions, with the loose ends pulling out of the tuck.

The instant tuck is particularly useful in tied long splices in wire rope formed of very stiff Wires. The tuck is easy for inexperienced splicing personnel to form, and there is no problem of wires working out of the core of the rope.

While the present invention has been described hereinabove in considerable detail, it is to be understood that the invention is not limited to the exact and specific particulars disclosed but it also encompasses such substitutes, modifications or equivalents as are included within the scope and spirit of the invention or pointed out in the appended claims.

I claim:

1. In a long splice in wire rope having an independent multistrand wire core and a plurality of outer strands, a tuck comprising:

(a) an outer strand the loose end of which is reduced in cross section for a short distance adjacent said rope,

(b) the wire core having several contiguous strands removed for several lays,

(c) the reduced section of said loose end being laid in the wire core in the void formed therein by the removal of said contiguous strands,

(d) the Wire rope having a section of its wire core removed for a short distance beyond the laid-in section of said outer strand, and

(e) the remainder of said loose end being inserted into said rope so as to occupy the void formed by removing said section of wire core therefrom.

2. In a long splice in a wire rope having an independent multistrand wire core and a plurality of outer strands, a method of tucking a loose end of an outer strand comprising:

(a) reducing the cross section of said loose end for a short distance adjacent said wire rope,

(b) removing several contiguous strands of said core for several lays,

(c) laying the reduced section of said loose end in the wire core in the void formed therein by the removal of said contiguous strands,

(d) removing a short section of the wire core beyond the laid-in section, and

(e) inserting the remainder of said loose end into the void formed by the removal of said section of wire core.

3. A method as recited in claim 2, in which the cross section of said loose end is reduced by removing some of the component Wires therefrom.

4. A method as recited in claim 2, in which the cross section of said loose end is reduced for a short distance adjacent said wire rope by a method comprising:

(a) removing some of the component wires from said loose end along the entire length thereof, and

(b) rebuilding the unlaid section of said loose end to substantially the diameter of the wire core.

5. In a long splice in a wire rope having an independent multistrand wire core and a plurality of outer strands, a tuck comprising:

(a) one outer strand from each of the two ropes which are spliced together,

(b) each of said outer strands having a section of reduced cross section in the area of the tuck,

(c) each of said reduced sections being inserted into the rope and laid in a void formed by the removal of several contiguous strands from the Wire core,

(d) a short section of said wire core being removed from said rope for a short distance beyond each of said laid-in sections of said outer strands, and

(e) the remainder of said outer strands being inserted into said rope so as to occupy the voids formed by removing said sections of wire core therefrom.

6. A tuck as `recited in claim 5, in which the cross section of said strands is reduced by removing some of the component wires therefrom.

7. In a long splice in a wire rope having an independent multistrand wire core and a plurality of outer strands, a tuck comprising:

(a) one outer strand from each of the two ropes which are spliced together being tied together in at least one knot,

(b) each of said outer strands having a decreased complement of wires in a section thereof in the area of the tuck,

(c) each of said decreased sections being inserted into References Cited by the Examiner the Tope and in a VOid formed th removal P of several contiguous strands from the wlre core,

(d) a short section of said wire core being removed 190,823 5/ 1877 Channon 57-142 X from said rope for a short distance beyond each of 5 386,690 7/ 1888 Collins 57-159 said laid-in sections of said outer strands, and 400,748 4/1889 C011 111S 57-159 (e) the remainder of said outer strands being inserted into said rope so as to occupy the voids formed by removing said sections of wire core therefrom. FRANK J- COHEN, Primary Examiner- D. E. WATKINS, Assistant Examiner. 

1. IN A LONG SPLICE IN WIRE ROPE HAVING AN INDEPENDENT MULTISTRAND WIRE CORE AND A PLURALITY OF OUTER STRANDS, A TUCK COMPRISING: (A) AN OUTER STRAND THE LOOSE END OF WHICH IS REDUCED IN CROSS SECTION FOR A SHORT DISTANCE ADJACENT SAID ROPE, (B) THE WIRE CORE HAVING SEVERAL CONTIGUOUS STRANDS REMOVED FOR SEVERAL LAYS, (C) THE REDUCED SECTION OF SAID LOOSE END BEING LAID IN THE WIRE CORE IN THE VOID FORMED THEREIN BY THE REMOVAL OF SAID CONTIGUOUS STRANDS, (D) THE WIRE ROPE HAVING A SECTION OF ITS WIRE CORE REMOVED FOR A SHORT DISTANCE BEYOND THE LAID-IN SECTION OF SAID OUTER STRAND, AND 